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Not sure which one? Ask us to confirm fitment first →For UK customers, prices include VAT, customs and delivery unless checkout states otherwise. Outside the UK, shipping is shown at checkout and local customs and taxes remain your responsibility.
Some products are made to order, imported or custom built. If timing matters, contact us before ordering and we will confirm the expected delivery timeframe.
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| Specification | Details |
|---|---|
| Vehicle application | 2022+ Ford Ranger Raptor 3.0 V6 EcoBoost petrol |
| Product | Process West Stage 2 intercooler |
| Core dimensions | 510 × 550 × 70 mm |
| Factory piping | Compatible with factory intercooler piping |
| Optional upgraded piping | Matching Process West Stage 2 arrangement, purchased separately |
| Existing Stage 1 piping | Requires the appropriate conversion parts |
| Installation summary | Plastic trimming and drilling, bracket/seal-plate work and original shutter-motor relocation; see complete guide |
| Stage 1 pipe conversion | PWRR0102B black / PWRR0102R red; sold separately |
| Reused mounting parts | Four original rubber intercooler grommets |
Repeated acceleration and sustained load give the Raptor’s charge-air cooling a serious job. The Process West Stage 2 intercooler adds a 510 × 550 × 70 mm bar-and-plate core, giving the compressed intake air more cooling surface before it reaches the engine.
The core can connect to the factory piping. Matching Stage 2 hard pipes are optional, and existing Process West Stage 1 pipes can use the appropriate conversion. Choose the route that suits the hardware you already own.
| Option | SKU | Price |
|---|---|---|
| Raw | PWRRIC02 | £1,770.31 |
| Black | PWRRIC02B | £1,770.31 |
The turbos heat air as they compress it. The intercooler removes heat before that charge enters the engine, using airflow across the core. More demanding use makes cooling capacity part of how consistently the engine can deliver its performance.
The larger Stage 2 core gives that job more cooling surface area. Its effect depends on ambient temperature, load and airflow reaching the cooling pack; it does not deliver one fixed temperature drop or horsepower gain on every Raptor.
| Intercooler | Price | Pipework | Installation difference | Why choose it |
|---|---|---|---|---|
| Turbosmart | £851.94 | Original / factory-style pipes | Factory shutter and shroud retained | Choose it to keep the factory shutter arrangement and avoid cutting. |
| Fenix cooler + pipes | £1,250.00 | Aluminium pipe kit included | Factory intercooler shroud removed | Choose the complete cooler-and-pipe upgrade in one purchase. |
| Process West Stage 1 | £1,276.44 | Factory pipes compatible; hard pipes separate | Shutter removal, motor relocation, drilling and trimming | Choose the factory-position Process West upgrade, with room to add its hard pipes later. |
| Process West Stage 2 | £1,770.31 | Factory pipes compatible; Stage 2 hard pipes separate | Trimming, plastic drilling and shutter-motor relocation | Choose the larger Process West core layout and allow for the more involved fitting. |
These prices cover the parts shown; fitting is separate. The table compares what you buy and what changes on the truck. The individual pages give the core dimensions and any product-specific test results.
The purchase is the Stage 2 intercooler core in your chosen finish, with the bracket, seal-plate and adapter arrangement shown in the installation guide. The original four rubber mounting grommets transfer to the new installation.
Factory pipes use the guide’s adapter arrangement. Dedicated Stage 2 hard pipes and Stage 1 conversion parts are separate purchases. That lets you keep serviceable pipework or complete the aluminium installation in the same visit.
The factory intercooler pipes can be retained. If you also want the matching hard-pipe upgrade, the Stage 2 kits are PWRRIC02B-pipe in black and PWRRIC02R-pipe in red, sold separately.
Already have Process West Stage 1 pipes? The dedicated conversion kit lets you keep that investment when moving to the larger core. The confirmed references are PWRR0102B in black and PWRR0102R in red. They provide the connecting parts for existing Stage 1 piping; they are separate from the intercooler.
PWRRIC02 is the raw cooler and PWRRIC02B is black. Both have the same core dimensions, so choose the finish that suits the look of your build.
The guide covers removal of front trim and the bumper section to access the original cooler, fitting the fan-shroud seal plate, drilling specified holes in plastic and trimming for the larger core. It also relocates the original shutter motor onto a supplied bracket. Allow for this front-end work in the fitting quote so the larger core and its surrounding parts are installed together.
The factory’s four rubber mounting grommets are reused. The guide identifies the new bracket, seal plate and hose adapters used with the factory-pipe arrangement; the adapters are skipped with the dedicated Stage 2 pipes. Lifting the new core into place is identified as a two-person step.
Allow for professional fitting and a leak check of the completed charge-air system. A bull bar, grille, winch or additional lights can affect space and airflow in front of the cooling pack. Include them in the fitting plan.
Mud and dust on the fins obstruct airflow. Inspect the core after off-road use and clean it using the recommended method without damaging the fins. Include mounts, pipes, clamps and hose connections in servicing.
An intake and crossover improve a different part of the air path before the turbos; this cooler works on the compressed charge afterwards. They can form a wider build together, but the intercooler can be purchased with compatible factory pipework. Engine-coolant and transmission-temperature problems need their own diagnosis.
| Specification | Details |
|---|---|
| Vehicle application | 2022+ Ford Ranger Raptor 3.0 V6 EcoBoost petrol |
| Product | Process West Stage 2 intercooler |
| Core dimensions | 510 × 550 × 70 mm |
| Factory piping | Compatible with factory intercooler piping |
| Optional upgraded piping | Matching Process West Stage 2 arrangement, purchased separately |
| Existing Stage 1 piping | Requires the appropriate conversion parts |
| Installation summary | Plastic trimming and drilling, bracket/seal-plate work and original shutter-motor relocation; see complete guide |
| Stage 1 pipe conversion | PWRR0102B black / PWRR0102R red; sold separately |
| Reused mounting parts | Four original rubber intercooler grommets |
When repeated acceleration, towing or sustained hard use makes additional charge-air cooling capacity valuable to the build. It is the larger-core step beyond Process West Stage 1.
Yes. Stage 2 supports the factory piping. The optional hard-pipe kit is a separate upgrade.
Yes, with the separate Stage 1-to-Stage 2 conversion kit: PWRR0102B in black or PWRR0102R in red. The pipes do not transfer unchanged.
Yes. The guide includes plastic trimming and drilling, brackets and shutter-motor relocation. Allow for that work when arranging installation.
Choose the finish you prefer. Raw PWRRIC02 and black PWRRIC02B share the same 510 × 550 × 70 mm core dimensions.
It cools the intake charge after the turbos. A coolant or transmission problem needs its own diagnosis and the appropriate cooling work.
Discuss the intercooler modification with your vehicle warranty provider. Factory-pipe compatibility does not settle the terms of that separate cover.
For UK customers, prices include VAT, customs and delivery unless checkout states otherwise. For customers outside the UK, local customs and taxes remain your responsibility, and shipping is shown at checkout. If a shipping option is not available, email us and we will prepare a tailored quote.
Many of the products we sell are made to order, imported or custom built, so a lead time may apply. If you need a part urgently, contact us before ordering and we will confirm the expected delivery timeframe and process.
Model year, engine, drivetrain, hardware and existing modifications can all change what fits. Check the applications and supplier notes above, or send us your exact vehicle and setup before ordering.
Send us your vehicle, year, current setup and any fitting date, event, trip or deadline before ordering. We will help check fitment, product choice and timing.
